A gentle solar module and its preparation method

Abstract

The present invention discloses a soft solar module and a preparation method thereof. The method includes: S1: dividing a first backplane, a transparent backplane, a first transparent front plate, and a second transparent front plate into N regions along the length vertical direction by an equal division line; S2: cutting small pieces of material at both ends of the equal division line; S3: laying the first backplane on an operating table and laying the cloth cut in S2 at the folding place; S4: laying a first back encapsulation film, a transparent backplane, and a second back encapsulation film according to a lamination structure; S5: placing a battery cell layer on the second back encapsulation film that has been laid and completing the bus bar connection; S6: laying a first front encapsulation film, a first transparent front plate, a second front encapsulation film, and a second transparent front plate on the battery cell layer; S7: integrally forming by a laminator. The present application uses a coated cloth for the folding place of the soft solar module to solve the folding problems of existing flexible modules, the problem of blocking the connection lines at the folding place, and the water tightness problem.

Description

Technical Field

[0001] The present invention relates to the technical field of solar photovoltaics, and in particular to a lightweight solar module and a preparation method thereof. Background Art

[0002] With the increasing global demand for sustainable energy, solar energy, as a clean and renewable energy source, has witnessed continuous innovation in its conversion technology. Among numerous solar energy conversion technologies, flexible photovoltaic modules are gradually changing our perception of traditional photovoltaic technologies and indicating a new technological revolution in the solar energy industry due to their unique technical characteristics and broad application prospects.

[0003] The research trend of lightweight flexible photovoltaic modules has been gradually rising due to their light and thin characteristics. Currently, lightweight flexible modules have problems such as being unable to be folded, inconvenient to carry, and poor scene compatibility. Summary of the Invention

[0004] Object of the Invention: Aiming at the problems and deficiencies existing in the prior art solutions, the present invention provides a lightweight solar module and a preparation method thereof.

[0005] The specific technical solution is as follows:

[0006] A preparation method of a lightweight solar module includes the following steps:

[0007] S1: Divide the first backplane, the transparent backplane, the first transparent front panel, and the second transparent front panel into N regions along the length vertical direction through equidistant lines, where N is a positive integer greater than or equal to 2, and the area of each region is the same;

[0008] S2: Cut small pieces of material at both ends of the equidistant lines, and then cut the fabric into small pieces of fabric with corresponding sizes according to the sizes of the small pieces of material. The positions where the small pieces of material are cut at both ends of the equidistant lines are the folding positions;

[0009] S3: Lay the first backplane on the operating table, and lay the small pieces of fabric cut in S2 at the folding positions;

[0010] S4: Lay the first back encapsulation film, the transparent backplane, and the second back encapsulation film in sequence from bottom to top according to the lamination structure;

[0011] S5: Place the battery cell layer on the second back encapsulation film that has been laid, complete the busbar connection. The battery cell layer includes N solar cell string plates, and the positions of the N solar cell string plates correspond to the N regions in S1. Conductive wires are used for electrical connection at the positions corresponding to the folding positions between the solar cell string plates;

[0012] S6: Lay the first front encapsulation film, the first transparent front plate, the second front encapsulation film, and the second transparent front plate on the cell layer in sequence from bottom to top, and lay the small piece of fabric cut in S2 at the folding position of the second transparent front plate;

[0013] S7: Use a laminator to laminate each layer in S3 - S6 into a lightweight solar module integrally;

[0014] S8: After laser cutting the lightweight solar module, installing corner guards, installing the bracket on the lightweight solar module with locking screws, and testing the performance, fold and store the lightweight solar module.

[0015] Further, the first back encapsulation film, the second back encapsulation film, the first front encapsulation film, and the second front encapsulation film are any one of the following materials: EVA, POE, PVB.

[0016] Further, the wire is a copper braid.

[0017] Further, the fabric is a waterproof coated fabric.

[0018] The corner guards are used to cover the defects at the connection between the fabric and the front and back plates;

[0019] The bracket is used to support the use of the solar panel.

[0020] Further, in S8, the corner guards are installed at both ends of the folding position of the module to protect the solar panel from damage and cover the defects at the connection between the fabric and the front and back plates.

[0021] Further, adding coated fabric in S3 and S6 covers the exposed connection between the two plates and provides waterproofness for the connection wires.

[0022] On the other hand, the present invention also provides a lightweight solar module, which is further prepared by the preparation method of the lightweight solar module described above.

[0023] Beneficial effects: This application uses coated fabric at the folding position of the lightweight solar module to solve the folding problems of existing flexible modules, cover the connection wires at the folding position, and solve the water tightness problem; the bracket is placed at the folding position to solve the folding thickness, usage scenario compatibility, and problem of cracked chips after folding. Description of the Drawings

[0024] Figure 1 It is a schematic diagram of the structure of the module prepared by the preparation method of the lightweight solar module in an embodiment provided by the present invention.

[0025] Figure 2 It is a schematic diagram of the first back plate in an embodiment provided by the present invention after cutting small pieces of material at both ends of the equal division line

[0026] Figure 3 Front view schematic diagram of a flexible solar module provided by the present invention.

[0027] Figure 4 Back view schematic diagram of a flexible solar module provided by the present invention.

[0028] Figure 5 Schematic diagram of the bracket of a flexible solar module provided by the present invention. Detailed implementation manners

[0029] Hereinafter, exemplary embodiments of the present application will be described in more detail with reference to the accompanying drawings. Although the exemplary embodiments of the present application are shown in the drawings, it should be understood that the present application can be implemented in various forms and should not be limited by the embodiments set forth herein. On the contrary, these embodiments are provided so that the present application can be more thoroughly understood and the scope of the present application can be fully conveyed to those skilled in the art.

[0030] As Figures 1-5 shown, a method for preparing a flexible solar module includes the following steps:

[0031] S1: Divide the first back plate 109, the transparent back plate 107, the first transparent front plate 103, and the second transparent front plate 101 into N regions along the length vertical direction by the equal division lines, where N is a positive integer greater than or equal to 2, and the area of each region is the same;

[0032] As Figure 2 shown, 600 is the equal division line.

[0033] S2: Cut off small pieces of material at both ends of the equal division line, and then cut the fabric into small pieces of fabric with corresponding sizes according to the sizes of the small pieces of material. The positions where the small pieces of material are cut off at both ends of the equal division line are the folding points. The small pieces of fabric are divided into 2 parts, namely the first small piece of fabric and the second small piece of fabric;

[0034] It should be noted that small pieces of material are cut off at both ends of the equal division line for the first back plate 109, the transparent back plate 107, the first transparent front plate 103, and the second transparent front plate 101.

[0035] Preferably, the shapes of the small pieces of material and the small pieces of fabric are both semi-circular and have the same size and dimensions. Figure 2 is a schematic diagram after cutting off the small pieces of material. It should be noted that the shape can also be a rectangle, or other shapes.

[0036] It should be noted that the number of the first small piece of fabric and the second small piece of fabric is the same.

[0037] S3: Lay the first backplane 109 on the operating table, and lay the first small piece of fabric cut in S2 at the folding place;

[0038] S4: Lay the first back encapsulation film 108, the transparent backplane 107 and the second back encapsulation film 106 in sequence from bottom to top according to the lamination structure;

[0039] S5: Place the battery cell layer 105 on the second back encapsulation film 106 that has been laid, complete the bus bar connection. The battery cell layer includes N solar cell string plates, and the positions of the N solar cell string plates correspond to the N areas in S1. Conduct electrical connection between the solar cell string plates at the positions corresponding to the folding place with wires;

[0040] S6: Lay the first front encapsulation film 104, the first transparent front plate 103, the second front encapsulation film 102, and the second transparent front plate 101 in sequence from bottom to top on the battery cell layer, and lay the second small piece of fabric cut in S2 at the folding place of the second transparent front plate;

[0041] S7: Use a laminator to laminate the layers in S3 - S6 into a soft solar module integrally;

[0042] S8: After laser cutting the soft solar module, installing corner protectors, installing brackets on the soft solar module, and testing the performance, fold and store the soft solar module.

[0043] It should be noted that the brackets are installed on the equidistant lines. The brackets can be installed on the soft solar module with locking screws 500.

[0044] Furthermore, the first back encapsulation film, the second back encapsulation film, the first front encapsulation film, and the second front encapsulation film include but are not limited to any one of the following materials: EVA, POE, PVB.

[0045] Furthermore, the wire is a copper braid.

[0046] Furthermore, the fabric is a waterproof coated fabric.

[0047] The corner protectors are used to cover the defects at the connection between the fabric and the front and back plates;

[0048] The bracket 300 is used to support the solar panel for use.

[0049] Furthermore, in S8, the corner protectors are installed at both ends of the folding place of the module to protect the solar panel from damage and cover the defects at the connection between the fabric and the front and back plates.

[0050] Furthermore, adding coated fabric in S3 and S6 covers the exposure at the connection between the two plates and provides waterproofness for the connection wires.

[0051] On the other hand, the present invention also provides a flexible solar module, and further, it is prepared by the preparation method of the above flexible solar module.

[0052] The front view of the flexible solar module is as Figure 3 shown, 200 is the corner guard, and 100 is the solar cell string plate.

[0053] The back view of the flexible solar module is as Figure 4 shown, 300 is the bracket. Figure 5 It is a schematic diagram of the bracket structure.

[0054] Beneficial effects: The present application uses a coated fabric for the folding part of the flexible solar module to solve the folding problems of existing flexible modules, the problem of blocking the connecting wires at the folding part, and the water tightness problem; the bracket is placed at the equal division line position to solve the problems of folding thickness, compatibility of use scenarios, and cracking of the folded part due to extrusion.

[0055] Finally, it should be noted that the above are only the preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments, or perform equivalent replacements for some of the technical features. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. A method for preparing a flexible solar panel, characterized in that: The following steps are involved: S1: Divide the first back plate, the transparent back plate, the first transparent front plate, and the second transparent front plate into N regions along the vertical direction of the length by equally dividing lines, where N is a positive integer greater than or equal to 2, and the area of ​​each region is the same; S2: Cutting off small pieces of material at both ends of the dividing line of the first back plate, the transparent back plate, the first transparent front plate, and the second transparent front plate, and then cutting the cloth into small pieces of cloth of corresponding sizes according to the size of the small pieces of material, the positions where the small pieces of material are cut off at both ends of the dividing line are folding positions, and the small piece of cloth is divided into two parts, namely a first small piece of cloth and a second small piece of cloth; S3: Lay the first backing plate on the operating table, and lay the first small piece of fabric cut in S2 at the folding part; S4: laying a first back side encapsulation film, a transparent back sheet, and a second back side encapsulation film in sequence from bottom to top according to a stacked structure; S5: placing a cell layer on the laid second back packaging film to complete bus connection, wherein the cell layer includes N solar cell string panels, the positions of the N solar cell string panels correspond to the N regions in S1, and electrical connections are made between the solar cell string panels at positions corresponding to the folded positions using wires; S6: Lay the first front packaging film, the first transparent front plate, the second front packaging film, and the second transparent front plate on the battery layer from bottom to top, and lay the second small piece of fabric cut in S2 at the fold of the second transparent front plate; S7: The layers in S3-S6 are laminated into one piece by a laminator to form a flexible solar module.

2. The method for preparing a flexible solar module according to claim 1, characterized in that: The S7 also includes: S8: After laser cutting the soft solar module, installing corner guards, installing brackets on the soft solar module, and testing performance, the soft solar module is folded and stored.

3. The method for preparing a flexible solar module according to claim 2, characterized in that: The step S8 of installing the bracket on the soft solar module includes: installing the bracket on the soft solar module using locking screws.

4. The method for preparing a flexible solar module according to claim 1, characterized in that: The first back-side encapsulation film, the second back-side encapsulation film, the first front-side encapsulation film, and the second front-side encapsulation film are made of any one of the following materials: EVA, POE, and PVB.

5. The method for preparing a flexible solar module according to claim 1, characterized in that: The conductor is a copper braided tape.

6. The method for preparing a flexible solar module according to claim 1, characterized in that: The fabric is a waterproof coated fabric.

7. The method for preparing a flexible solar module according to claim 1, characterized in that: The shapes of the small pieces of material include: semicircle and rectangle.

8. A soft solar panel, characterized in that: The flexible solar module is prepared by the method for preparing the flexible solar module according to any one of claims 1 to 7.

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